Spring assembly



April 30, 1963 MELEN I 3,087,169

SPRING ASSEMBLY Filed July 5, 1961 United States Patent 3,087,169 SPRKNGASSEMBLY Ralph B. Melon, Swampscott, Mass, assignor to Flex-O- LocCorporation, Fisher-ville, Mass., a corporation of Massachusetts FiledJuly 3, 1%1, Ser. No'. 121,468 Claims. (Cl. 5259) This invention relatesto spring assemblies of the type used in mattresses, as box springs, forseat cushions, chair backs and the like. More particularly the presentinvention relates to spring construction using spaced rows of coilsprings and specifically to tie wires and formations used to fastenadjacent coil springs of a row to one another and to hold the springs ofthat row in .proper spaced relation to the springs of the next row.

One object of the present invention is to provide an improved tie wireconstruction which is relatively inexpensive and easily applied to aspring assembly.

Another object is to provide a form of tie wire con nection which uses aminimum of material and wire of less costly grade than that now usuallyrequired.

A further object is to provide a dependable tie wire formation which isfree from projections or sharp edges which, after a period of use, mightpuncture the upholstery covering the spring assembly.

A still further object is to provide a tie wire connection for securingadjacent coil springs together in a spring assembly in a firm mannerwhile at the same time permitting enough movement between the coilsprings so that the assembly provides a comfortable yielding support.

In one embodiment of the invention, these objects are achieved byoverlapping the outer turns of adjacent coil springs in each row of aspring assembly, by inserting tie wires underneath the outer turns ofthe springs where they overlap, by forming generally U-shaped loops ineach tie wire where it extends next to the overlapped turns of the coilsprings, passing the loops of the tie wire upwardly through the openingsbetween the intersecting arcs of the overlapped coil springs in each rowand wrapping or twisting the loops in a single direction over and aroundboth turns where they overlap. The material used for the tie wire is ofa kind less costly than that usually required for such purposes, whilethe frame members and coil springs of the assembly may be of standardmaterials and forms.

Other objects and further details of that which is believed to be noveland included in this invention will be clear from the followingdescription and claims, taken with the accompanying drawing in which isillustrated an example of spring assembly embodying the presentinvention and incorporating the improved tie wire with loop wrapped in asingle direction.

In the drawing:

FIG. 1 is a fragmentary plan view of a corner of a spring assemblyaccording to the invention showing how a tie Wire secures together twocoil springs in one row of such springs in the assembly;

FIG. 2 is an enlarged sectional View taken on the line and in thedirection of the arrows 2-2 of FIG. 1;

FIG. 3 is a side view asif seen looking from the lefthand side of FIG.2;

FIG. 4 is another side view as if seen looking from the right-hand sideof FIG. 2;

FIG. 5 is a perspective view of a section of the tie wire ice alone,showing the U-shaped loop in the tie wire after it has first beenformed, butbefore it is wrapped or twisted around the turns of coilsprings;

, FIG. 6 is a perspective view like FIG. 5, but showingthe U-shaped loopas it will appear after the first part of the wrapping has taken place;and

FIG. 7 is another perspective view showing the loop as it will appearcompletely formed; that is, after it has been wrapped entirely aroundthe two turns of the coil springs.

A spring assembly according to this invention usually includes an outerframe 10 of relatively stiff heavy wire. After the spring assembly iscompleted, it is intended to be covered with upholstery. There is oftenboth an upper and lower frame in spring assemblies of the kind herecontemplated, and the same construction is used on each side of theassembly. Only one side will be shown and described. In known fashion,helical wires 12 may be used to hold the outer circular turns 14 and 16of the usual coiled springs 20 and 22 to the frame. Tie wires '18, ofwhich there is a part of but one shown in FIG. 1, are used to fasten theturns 14 and 16 together in overlapping relation and to space similarrows of coiled springs from one another. It will be noted that the tiewire 18 preferably extends under the overlapping portions of both thecoil turns 14 and 16.

In order to secure the overlapped circular turns 14 and 16 together, aU-shaped loop with a bend or bight 24 is provided in the tie wire 18wherever this tie wire passes under an opening 25 formed by theintersecting arcs of the overlapping portions of turns such as 14 and 16in spaced rows of coiled springs. The coiled springs like 20 and '22 maybe of a usual standard double-conical type. In the tie wire the bight 24may be formed by bending the wire 13 first, before passing it upwardlythrough the opening 25, or the bight may be formed by forcing or drawinga part of the wire 18 through the opening between the overlapping turnsof the coil springs, the formation of the bight being simultaneous withits passage through the opening.

In a geometrical sense, it may be noted that the overlapped end turns 14and 1-6 form intersecting arcs, one turn forming one side and the otherturn forming the other side of the lenti'cular or pointed ellipticopening 25. The straight parts of the tie wire 18 extend parallel to themajor dimension of the opening 25 and in plan view the tie wire ischordal to both the arcs where they intersect.

In wrapping or twisting the loop to secure the coils together, the legsof the loop are first passed upwardly through the opening 25 and thenlaterally over the upper (most remote) overlapping turn 16 as at 26,then down- Wardly outside of the opening 25 and turn 16, around, underand outside the lower turn 14 as at 28, and then back up and at leastpartly over the turn 14, where the bend or bight of the loop 24 holdsthis turn in place. Note that when this loop was wrapped or twistedaround the coil turns it was moved in but a single direction of rotationthrough substantially 360. This unidirectional wrapping or twistinglends itself readily to simple tools or machines for performing theoperation. No difficult manipulation of the tie wire is necessary inorder to complete a firm connection between adjacent coil springs in theassembly. There is a limited hi-nging action possible between the joinedturns of adjacent con springs, but this is sufficient to allowcompression of the coil springs while holding them in proper positionfirmly anchored with respect to one another.

It is to be understood that the tie wire 1%, beyond the single twistedloop shown in FIG. 1, extends in a straight section as at 30approximately to the center line of a next row or bank of coil springsin the frame (not shown), Where similar overlapping turns are securedtogether by a similar loop wrapped in a similar fashion around theturns. The straight sections between the twisted loops of coursedeter-mine alignment of the rows of coil springs in properly spacedrelation, the loops holding the rows apart as well as joining together apair of adjacent coil springs Within one row of the assembly.

The form of loop used in the tie wire according to the present inventionis very economical of the amount of wire used. Furthermore, it has beenfound possible according to this invention to use for the tie wires anordinary commercial grade spring wire which, because it requires noclinching, may be relatively soft compared to the usual material usedfor tie Wires. Because the bight of the loop is round and smooth, itpresents no sharp edges which might damage upholstery applied outside ofthe spring assembly.

It should also be noted that the tie wire proper is located preferablyon the inner or underside of the lower one of the overlapping turns,thus avoiding the formation of objectionable ridges in the upholsterysurrounding the spring assembly 'by the projection of extensions 38 intothe mass of upholstery. However, if a stiffened reinforcing layer ofmaterial is used between the spring assembly and the upholstery coveringit, the tie wires might be located on the upper or outer side of theoverlapping turns without objection. In that case the loop would bewrapped first around the inside or lower one of the overlapping turns,this being the turn most remote from the tie wire proper.

Referring to the preferred form shown, the fact that the tie wire loopfirst passes upwardly through the lenticular opening 25 positivelyprevents shifting of the turns in a horizontal direction away from eachother. In order to insure the locking action which prevents movement ofthe overlapping turns away from each other in a horizontal direction,the loop should pass through the opening 25 until it is beyond theuppermost or most remote one of the two turns. Then the wrapping ortwisting of the loop should start in a lateral direction radiallyoutside of (away from the center of) that uppermost turn and radiallyinwardly of (toward the center of) the other turn, which is lowermostand nearest the tie wire. The straight portions of the tie wireextending on either side of the loop underlie portions of both turns andsupport them. Therefore, where the loop passes over the top of theuppermost turn 16, as at 26, it acts as a hook and limits movement ofboth turns away from the tie wire in an upward direction. The portionsof the loop which pass over the outside circumferences of the turn 16and turn 14 hold these turns and their respective coils against shiftingany further toward each other in a horizontal direction. By continuingto wrap the loop around until its bight lies at least partly over thelowermost turn 14-, and near the beginning of the loop, the tie wireproper is prevented from twisting when the spring assembly is in usebecause the loop is thus hooked over and prevented from swinging away orbecoming disengaged from that turn.

As will be evident from the foregoing description, certain aspects ofthis invention are not limited to the particular details set forth as anexample, and it is contemplated that various and other modifications andapplications of the invention will occur to those skilled in the art. Itis therefore intended that the appended claims shall cover suchmodifications and applications as do not depart from the true spirit andscope of this invention.

What is claimed as new and is desired to be secured by Letters Patent ofthe United States is:

1. In a spring assembly of the type including spaced rows of coilsprings with outer circular turns of adjacent springs overlapping oneWith another in each row to form a lenticular opening where the arcs ofeach pair of said turns intersect, that improvement in means for joiningthe overlapping circular turns of a pair of adjacent springs in one rowtogether and for holding joined springs of one row spaced from those ofthe next row, comprising a straight tie wire extending under saidopenings and having U-shaped loops spaced apart therealong coincidingwith the desired spacing between centers of said spaced rows of springs,each loop extending upwardly through one said lenticular opening betweenoverlapping outer turns of a pair of adjacent coil springs in one rowand being wrapped unidirectionally around both said outer turns wherethey overlap, first radially outside the overlapping circular turn mostremote from said tie wire and forming one side of said opening, thendownwardly and laterally under and across said opening, then upwardlyoutside the circular turn nearest said tie wire and forming the otherside of the opening with the bight of the loop hooked over thelast-named circular turn.

2. In a spring assembly of the type including spaced rows of coilsprings with outer circular turns of adjacent springs overlapping onewith another in each row to form a lenticular opening where the arcs ofeach pair of said turns intersect, that improvement in means for joiningthe overlapping circular turns of a pair of adjacent springs in one rowtogether and for holding joined springs of one row spaced from those ofthe next row, comprising a straight tie wire having U-shaped loopsspaced apart therealong coinciding with the spacing between centers ofsaid spaced rows of springs, each loop extending through one saidlenticular opening between overlapping turns of a pair of adjacent coilsprings in one row and being wrapped unidirectionally around both saidturns where they overlap, first outside the overlapping circular turnmost remote from said tie wire and forming one side of said opening,then across said opening and finally outside the circular turn nearestsaid tie wire and forming the other side of said opening.

3. In a spring assembly wherein there are a plurality of series of coilsprings and an end turn of one of a pair of adjacent coil springs in aseries of springs overlaps the end turn of another spring formingintersecting arcs, a tie wire extending under both the overlapping turnsand chordal to both the intersecting arcs, an elongated U- shaped loopin the tie wire extending upwardly through the space formed within theintersecting arcs, then first radially outwardly over the uppermostoverlapping turn, then around and beneath iboth overlapping turns, andaround the lowermost overlapping turn with the bight of the U againextending in the first mentioned radial direction and adjacent and abovethe start of the loop, said tie wire being continued across said springassembly to an adjacent pair of overlapping turns, with a U-shaped loopin the wire identically extending between and around the overlappingturns of said adjacent pair.

4. In a spring assembly wherein an end turn of one of two adjacent coilsprings overlaps the end turn of the other forming intersecting arcs, atie wire extending across both the overlapping turns and chordal to boththe intersecting arcs, an elongated U-shaped loop in the tie wireextending through the space formed within the intersecting arcs, thenfirst radially outwardly across the overlapping turn most remote fromsaid tie wire, then around both overlapping turns in the oppositedirection, and finally around the overlapping turn nearest said tie wirewith the bight of the U again extending in the first mentioned radialdirection and adjacent the start of the loop.

5. A tie formation for overlapped circular turns of coil springs whichform a lenticular opening wher their circumferential arcs intersect,comprising a tie wire with generally straight portions extending next toand across said overlapped turns, parallel to the major dimension ofsaid opening, a -U-shaped loop in said wire with legs extending throughsaid opening, the legs of the loop further being wrapped around bothsaid overlapped turns in a single direction with the bight of the loophooked over the circular turn which is next to the straight portions ofthe tie wire, whereby to hold both turns against any but limitedmovement relative to each other and said tie wire.

References Cited in the file of this patent UNITED STATES PATENTS Malleyet al. Oct. 29, Rickerson Apr. 20, Levine Sept. 1, Bank July 18,

1. IN A SPRING ASSEMBLY OF THE TYPE INCLUDING SPACED ROWS OF COILSPRINGS WITH OUTER CIRCULAR TURNS OF ADJACENT SPRINGS OVERLAPPING ONEWITH ANOTHER IN EACH ROW TO FORM A LENTICULAR OPENING WHERE THE ARCS OFEACH PAIR OF SAID TURNS INTERSECT, THAT IMPROVEMENT IN MEANS FOR JOININGTHE OVERLAPPING CIRCULAR TURNS OF A PAIR OF ADJACENT SPRINGS IN ONE ROWTOGETHER AND FOR HOLDING JOINED SPRINGS OF ONE ROW SPACED FROM THOSE OFTHE NEXT ROW, COMPRISING A STRAIGHT TIE WIRE EXTENDING UNDER SAIDOPENINGS AND HAVING U-SHAPED LOOPS SPACED APART THEREALONG COINCIDINGWITH THE DESIRED SPACING BETWEEN CENTERS OF SAID SPACED ROWS OF SPRINGS,EACH LOOP EXTENDING UPWARDLY THROUGH ONE SAID LENTICULAR OPENING BETWEENOVERLAPPING OUTER TURNS OF A PAIR OF ADJACENT COIL SPRINGS IN ONE ROWAND BEING WRAPPED UNIDIRECTIONALLY AROUND BOTH SAID OUTER TURNS WHERETHEY OVERLAP, FIRST RADIALLY OUTSIDE THE OVERLAPPING CIRCULAR TURN MOSTREMOTE FROM SAID TIE WIRE AND FORMING ONE SIDE OF SAID OPENING, THENDOWNWARDLY AND LATERALLY UNDER AND ACROSS SAID OPENING, THEN UPWARDLYOUTSIDE THE CIRCULAR TURN NEAREST SAID TIE WIRE AND FORMING THE OTHERSIDE OF THE OPENING WITH THE BIGHT OF THE LOOP HOOKED OVER THELAST-NAMED CIRCULAR TURN.